Resin Radome for Millimeter Wave Transmission
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Solution Overview
Problem
Radar equipment radomes face challenges in efficiently transmitting millimeter waves while maintaining mechanical and dimensional stability, impact resistance, and minimizing dielectric loss.
Innovation Solution
A thermoplastic resin composition comprising rubbery polymer-reinforced vinyl-based resins, polyolefin resins, and polycarbonate resins with specific content ratios and inorganic fillers, designed to have a low dielectric constant and mold shrinkage rate, is used in the radome to enhance electromagnetic wave transmission and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a radome is formed entirely of a material that easily transmits electromagnetic waves, then electromagnetic wave transmission is improved, but mechanical strength and dimensional stability deteriorate
Solution Approach 1:
The radome is constructed using a composite material system consisting of a resin compact containing a specific resin composition (polyolefin resin, polycarbonate resin, and cyclic olefin resin in controlled ratios) combined with an inorganic filler (such as glass fibers or mineral fillers). This composite structure achieves both low dielectric constant (2.6-3.2) for excellent electromagnetic wave transmission and sufficient mechanical strength through the reinforcement provided by the inorganic filler network.
Solution Approach 2:
The patent precisely controls the dielectric constant and loss tangent parameters of the resin composition by adjusting the ratios of polyolefin resin (30-80 parts), polycarbonate resin (10-40 parts), and cyclic olefin resin (5-20 parts), along with inorganic filler content (20-60 parts per 100 parts resin). This parameter optimization enables the material to simultaneously achieve low electromagnetic wave attenuation and adequate mechanical properties.
2Loss of energy
If a radome is formed entirely of a material that easily transmits electromagnetic waves, then electromagnetic wave transmission is improved, but heat resistance and impact resistance deteriorate
Solution Approach 1:
The resin compact combines multiple resin types (polyolefin, polycarbonate, cyclic olefin) with inorganic fillers to create a composite material that balances electromagnetic transparency with thermal and mechanical reliability. The polycarbonate component provides heat resistance, while the crosslinked structure and inorganic filler network enhance impact resistance, all while maintaining low dielectric loss for millimeter wave transmission.
Solution Approach 2:
The patent applies different functional characteristics to different components: the resin matrix provides electromagnetic wave transmission and flexibility, while the inorganic filler network provides structural rigidity, heat resistance, and impact strength. This local differentiation of material functions within the composite enables simultaneous achievement of transmission efficiency and environmental reliability.
3Loss of energy
If the dielectric constant of the radome material is reduced to improve electromagnetic wave transmission, then transmission efficiency is improved, but mold shrinkage rate increases
Solution Approach 1:
The patent establishes specific parameter ranges to balance dielectric properties and molding stability: dielectric constant controlled at 2.6-3.2, loss tangent at 9.0×10^-3 or less, and mold shrinkage rate at 1.5% or less. These parameters are achieved through controlled composition ratios of the resin system and inorganic filler content (20-60 parts per 100 parts resin), which provide both low electromagnetic attenuation and dimensional stability during molding.
Solution Approach 2:
The incorporation of inorganic fillers (glass fibers, mineral fillers) into the resin matrix creates a composite structure where the filler network restrains mold shrinkage while the resin matrix maintains low dielectric constant. This composite approach decouples the trade-off between electromagnetic transmission and manufacturing precision by providing structural support independent of the resin's dielectric properties.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively transmits millimeter waves with minimal reflection or absorption, providing marked impact resistance and dimensional stability, making it suitable for radar equipment applications.
Implementation Method 1
the resin component having a low dielectric constant and a low dielectric loss tangent, and being excellent in transmission of an electromagnetic wave such as a millimeter wave
Data Source
AI summary
The present invention is a resin component disposed in a path of a beam emitted from a radar equipment, the resin component consisting of a thermoplastic resin composition containing at least one thermoplastic resin selected from a group consisting of a rubbery polymer-reinforced vinyl-based resin wherein a polymer part derived from a rubbery polymer and a vinyl-based resin part containing a structural unit derived from a vinyl-based monomer are chemically bonded, a polyolefin resin, and a polycarbonate resin, and having a dielectric constant of 2.9 or less, and a mold shrinkage rate of 1.2% or less as measured in accordance with JIS K 7152-4. This resin component can be used as a radome and may constitute part of a radar device.